System and method for condensing moisture in a bioreactor gas stream

ABSTRACT

Disclosed herein is a system and method for condensing moisture in a gas stream entering or leaving a bioreactor, the system comprising: a contact condenser container fluidically coupled to the bioreactor through an exhaust line; a condensate accumulator fluidically coupled to the contact condenser container through at least a first condensate line and a second condensate line; the condensate accumulator further fluidically coupled to the bioreactor through a condensate overflow line; a first condensate control device disposed on the first condensate line and configured to control a flow of condensate leaving the contact condenser container and entering the condensate accumulator; and a second condensate control device disposed on the second condensate line and configured to control a flow of condensate leaving the condensate accumulator to be mixed with the gas stream.

TECHNICAL FIELD

The present invention relates generally to systems and methods for usewith disposable bioreactors or with non-disposable tank bioreactors.

BACKGROUND

Cell culturing is an essential step in manufacturing biologicalproducts, and may be carried out in disposable bioreactors or innon-disposable bioreactors such as steel tank vessels. Oxygen iscontinuously supplied to promote cell growth, and carbon dioxide isremoved. A gas stream entering or leaving a bioreactor may containmoisture entrained within the gas stream. The moisture in themoisture-containing gas stream may condense as the gas stream passesthrough a filter or other system components. The moisture and/orcondensation may be detrimental to the functioning of the filter orother system components. Typically a condenser is used for condensingmoisture in a moisture-containing gas stream entering or leaving abioreactor.

A number of yet un-solved problems are inherent in currently availablecondenser designs for use with bioreactors. Some related art designincorporate several functionally different areas such as, for example,subducts and different cooling and heating zones, that result in acomplex and costly assembly requiring special tooling, specially moldedor machined components. Because related art designs are complex and tendto be expensive, such condensers are not truly disposable.

Currently available condensers may have another drawback in that thecondensate that is generated from condensing moisture in amoisture-containing gas stream is wasted by being poured into theenvironment to get rid of it.

Yet another drawback of currently available condenser designs is relatedto the bioreactor reaction volume loss. If the water vapor from thebioreactor reaction mixture is lost over time and not replenished, thenthe osmolality of the bioreactor reaction mixture may change to anundesirable level.

Therefore, there is a need for an improved system, in particular, atruly disposable or single-use system and corresponding method thatprovide a means to reduce the moisture content of a moisture-containinggas stream within a bioreactor system before it passes to a filter orother system components, minimize wasting the condensate generated, andminimize the loss of the bioreactor reaction volume.

SUMMARY

The embodiments disclosed in the present invention for the system andassociated method for condensing moisture in a bioreactor gas streamovercome many of the problems found in currently available condensers.However, the embodiments disclosed in the present invention should notbe limited to solving only the problems stated in the applications, butmay solve other problems in other areas.

The invention includes, but is not limited to, the followingembodiments:

One embodiment includes a system for condensing moisture in a gas streamentering or leaving a bioreactor, the system comprising: a contactcondenser container fluidically coupled to the bioreactor through anexhaust line; a condensate accumulator fluidically coupled to thecontact condenser container through at least a first condensate line anda second condensate line; the condensate accumulator further fluidicallycoupled to the bioreactor through a condensate overflow line; a firstcondensate control device disposed on the first condensate line andconfigured to control a flow of condensate leaving the contact condensercontainer and entering the condensate accumulator; and a secondcondensate control device disposed on the second condensate line andconfigured to control a flow of condensate leaving the condensateaccumulator to be mixed with the gas stream.

Another embodiment includes a method for condensing moisture in a gasstream entering or leaving a bioreactor, the method comprising:directing the gas stream leaving the bioreactor and entering the contactcondenser container; producing a condensate inside the contact condensercontainer; directing and controlling a flow of the condensate leavingthe contact condenser container and entering the condensate accumulator;and directing and controlling a flow of at least a portion of thecondensate leaving the condensate accumulator to be mixed with the gasstream.

Yet another embodiment includes a system for condensing moisture in agas stream entering or leaving a bioreactor, the system comprising: acontact condenser container fluidically coupled to the bioreactorthrough an exhaust line; a junction fitting fluidically coupled to thecontact condenser container through a first and a second condensateline; the condensate accumulator further fluidically coupled to thebioreactor through a condensate overflow line; a first condensatecontrol device disposed on the first condensate line and configured tocontrol a flow of condensate leaving the contact condenser containerinto the junction fitting; and a second condensate control devicedisposed on a second condensate line and configured to control a flow ofcondensate leaving the condensate accumulator to be mixed with the gasstream, wherein the flow of condensate is used to provide cooling to thegas stream.

BRIEF DESCRIPTION OF THE DRAWINGS

The various advantages of the embodiments will be apparent to oneskilled in the art by reading the following specification and appendedclaims, and by referencing the following drawings, in which:

FIG. 1 is a schematic drawing of an example of a system according to anembodiment.

FIG. 2 is a schematic drawing of an example of a system according to anembodiment.

FIG. 3 is a cross sectional view of the example of a system according toan embodiment (partial view).

FIG. 4 is a schematic drawing of an example of a system according to anembodiment.

FIG. 5 is a schematic drawing of an example of a system according to anembodiment.

FIG. 6 is a schematic drawing of an example of a system according to anembodiment.

FIG. 7 is a schematic drawing of an example of a system according to anembodiment.

FIG. 8 is a cross sectional view of the example of FIG. 7 (partialview).

FIG. 9 is an exploded view of the example of FIG. 7 (partial view).

FIG. 10 is a schematic drawing of an example of a system according to anembodiment.

FIG. 11 is a cross sectional view of the example of FIG. 10 (partialview).

FIG. 12 is an exploded view of the example of FIG. 10 (partial view).

FIG. 13 is a schematic drawing of an example of a system according to anembodiment.

FIG. 14 is a cross sectional view of the example of FIG. 13 (partialview).

FIG. 15 is an exploded view of the example of FIG. 13 (partial view).

FIG. 16 is a schematic drawing of an example of a system according to anembodiment.

FIG. 17 is a perspective view of an example of a contact condensercontainer according to an embodiment.

FIG. 18 is an exploded view of the example of FIG. 17.

FIG. 19 is a perspective view of an example of a condenser accumulatoraccording to an embodiment.

FIG. 20 is a perspective view of an example of a condenser accumulatoraccording to an embodiment.

FIG. 21 is a perspective view of an example of a condensate primingsystem according to an embodiment.

FIG. 22 is a schematic drawing of an example of a method according to anembodiment.

DETAILED DESCRIPTION

Any examples or illustrations given herein are not to be regarded in anyway as restrictions on, limits to, or express definitions of, any termor terms with which they are utilized. Instead, these examples orillustrations are to be regarded as being described with respect tovarious particular embodiments and as illustrative only. Those ofordinary skill in the art will appreciate that any term or terms withwhich these examples or illustrations are utilized will encompass otherembodiments that may or may not be given therewith or elsewhere in thespecification and all such embodiments are intended to be includedwithin the scope of that term or terms. Language designating suchnon-limiting examples and illustrations includes, but is not limited to:“for example”, “for instance”, “such as”, “e.g.”, “including”, and “inone (an) embodiment”.

The term “bioreactor” as used herein generally refers to a device orapparatus in the form of a closed chamber or vessel in which livingorganisms such as mammalian cells, bacteria or yeast synthesizesubstances useful, for example, to the pharmaceutical industry undercontrolled conditions favorable to that specific organism. Traditionallybioreactors were closed, rigid stainless steel vessels in which theorganisms were grown. The term “bioreactor” as used herein may be rigidor disposable, single-use bioreactor.

The term “disposable” or “single-use” as used herein in the context of abioreactor generally refers to a flexible container, liner or bagincorporating all of the functional aspects required of a traditionalbioreactor which can be filled with the materials required for thegrowth of mammalian cells, bacteria or yeast and is designed with theintention that it be disposed of at the completion of a singleproduction run.

The term “moisture-containing gas stream” as used herein generallyrefers to a gas stream entering or leaving a bioreactor and containsmoisture entrained within the moisture-containing gas stream. Themoisture-containing gas stream may be referred to as a “gas stream” or a“moist gas stream”.

The term “dry gas stream” as used herein generally refers to a gasstream with moisture entrained within the gas stream substantiallyremoved.

The term “contact condenser container” as used herein generally refersto a condenser container in which a recycled condensate makes directcontact with a moisture-containing gas stream to assist in removingmoisture from the gas stream.

For a discussion of the condenser container, see for example, US20120260671 A1 published on Oct. 18, 2012, which is incorporated hereinby reference. The condenser container may be either a single use,flexible, nonporous bag comprising, for example, a flexible polyethylenematerial or film, or a rigid or a semi-rigid container instead of aflexible bag. The condenser container may be referred to as a “bag”, a“condenser bag” or a “flexible bag”.

The term “recycled condensate” as used herein generally refers to arelatively cool condensate that is initially generated from condensingmoisture in a relatively hot moisture-containing gas stream entering orleaving a bioreactor and is reused or recycled by either having at leasta portion of the relatively cool condensate introduced back into andmixed with the moisture-containing gas stream or having a portion of thecool condensate introduced back into a bioreactor. The recycledcondensate may be referred to as a “condensate”, a “cool condensate”, ora “relatively cool condensate”.

The term “condensate recycling process” as used herein generally refersto a process involving reusing or recycling of a relatively coolcondensate generated from condensing moisture in a moisture-containinggas stream entering or leaving a bioreactor.

The term “condensate accumulator” as used herein generally refers todevices or apparatus used with bioreactors. The condensate accumulatoris configured to hold or store the a relatively cool condensatecollected from a condenser container prior to at least a portion of thecondensate being introduced back into and mixed with a relatively hotmoisture-containing gas stream. The condensate accumulator may be eitherrigid stainless steel vessels or disposable and/or single-use systemsand are compatible with both disposable and non-disposable bioreactors.

The term “condensate flow control device” as used herein generallyrefers to devices or apparatus used to direct and/or control the flow ofthe condensate. The condensate flow control device may comprise a pump,a check valve, or a nozzle, a pressurized air source, or a combinationthereof. The features of the condensate flow control device aredescribed in more details in the detailed description section. The terms“condensate flow control system” and “condensate flow control device”may be used interchangeably.

The term “condensate overflow control device” as used herein generallyrefers to devices or apparatus used to direct and/or control thecondensate overflow from the condensate accumulator to the bioreactor.The condensate overflow control device may comprise a pump, a checkvalve, a nozzle, or a pressurized air source, or a combination thereof.

The term “disposable” or “single-use” as used herein in the context of acontact condenser container, a condensate accumulator, a condensate flowcontrol device, and a condensate overflow control device generallyrefers to a device designed to be low cost and to incorporate materialswhich can be easily disposed of using commonly available wasteprocessing infrastructure and not requiring special disposal procedures.Non-limiting examples of materials which can be easily disposed ofcomprise polyethylene, polypropylene, polyester, or polyamide, orcombination thereof. The materials may further comprisegamma-irradiation stable materials. Non-limiting examples of materialsthat are considered gamma-irradiation stable comprise polyethylene,polypropylene, polyester, polyamide, polysulfone, polycarbonate,polyvinylidene fluoride, or polyurethane, or combination thereof. Thedevice may further comprise pre-sterilized components with sanitaryconnectors or tubings suitable for sterile welding.

The term “coupled” as used herein is intended to signify that distinctelements are joined, linked or otherwise connected together directlyand/or indirectly.

The term “flow direction” as used herein is generally represented by areference numeral 110. It is to be understood that 110 is not limited toone specific flow direction arrangement, rather, 110 may be used torepresent various flow arrangements for a fluid flow.

In one embodiment, a relatively cool condensate is generated while arelatively hot moisture-containing gas stream passes through a condensercontainer. Instead of being sent to waste, the condensate generated isdirected to a condensate accumulator and recycled by having at least aportion of the condensate transferred out of the condensate accumulator,introduced back into and mixed with the moisture-containing gas streamto provide further cooling and condensation of the moisture in the gasstream. Recycling condensate increases the overall efficiency of themoisture removal from the moisture-containing gas stream. The mixing ofthe recycled condensate with the moisture-containing gas stream mayoccur either in a location inside the exhaust line coupling thebioreactor to the contact condenser container or inside the contactcondenser container itself.

The condensate recycling process may comprise three stages. The initialstage comprises a “priming stage” which occurs during the early phase ofa bioreactor run when very little cool condensate is produced inside thecondenser container. Therefore, there may not be sufficient condensateto introduce a continuous flow of recycled condensate back into themoisture-containing gas stream. Alternatively, the priming may be donemanually by adding sterile filtered water to the condensate accumulatorvia a condensate priming system comprising a priming fitting and asterile filter, which are described in details in FIG. 21.

The second stage occurs when more recycled condensate is introduced backinto the gas stream and facilitates more efficient moisturecondensation. As a result a continuous flow of recycled condensate beingintroduced back into the gas stream may be established. This is a stagewhen the cooling efficiency of the contact condenser container becomesgreater, and is considered to be a positive feedback stage.

As more and more condensate is produced the recycling process reaches athird stage where the condensate level inside the condensate accumulatorincreases to a condensate overflow mark and the overflow condensate istransferred to the bioreactor. Thus, negative impacts due to thebioreactor reaction volume loss may be minimized. At the third stage,there is a relatively constant flow of recycled condensate back into thegas stream since almost all of the recycled condensate introduced backinto and/or mixed with the gas stream is quickly recovered from thecontact condenser container and transferred to the condensateaccumulator.

The condensate recycling process may be controlled or adjusted by acondensate flow control system. The condensate flow control system maybe used in conjunction of a bioreactor control system including, but notlimited to, various bioreactor sensors to provide further control of thecondensate recycling process. Non-limiting examples of bioreactorsensors include sensors for pH, concentration, or osmolality, orcombination thereof.

The condensate generated within the contact condenser container may bereleased or drained from the contact condenser container eithercontinually or periodically. The condensate may be drained through aninlet port fitment. Alternatively, there may be a separate fitment, forexample, a hose barb (not shown) attached to a surface of the contactcondenser container specifically for draining the condensate. The hosebarb may be used for attaching and securing a tubing to collect thecondensate.

The condensate leaving the condensate accumulator may be introduced backinto and mixed with the gas stream in a form of a spray of condensatedroplets (a spray type contact condenser container). Alternatively, thecondensate may be introduced back into and mixed with the gas stream ina form of a gravity flow down the interior sides of the exhaust line tobe mixed with the gas stream (a drip type contact condenser container).

An internal cooling surface or device may be used to provide additionalcooling to the interior of the contact condenser container. For example,in FIG. a tubing may be disposed within the contact condenser containerto provide additional internal cooling. A cooling liquid or coolant mayflow through the tubing. The internal cooling device also increase theturbulence within the moisture-containing gas stream as it passesthrough the contact condenser container to further promote thecondensation of the moisture in the gas stream.

An external cooling surface or device may also be used to provideadditional cooling to the contact condenser container. One or moreexternal cooling surfaces may be positioned to come into contact withthe external surface of the contact condenser container. A peristalticpump or a pump with a disposable pump head may be used to provide acoolant flow for the additional external cooling to the contactcondenser container. These external cooling surfaces may be cooled bythermoelectric Peltier modules. For example, a thermoelectric Peltiermodule (TE Technology, Inc., Traverse City, Mich.) may be used.

The advantages of the condensate recycling process disclosed herein maybe even more significant when being used with a bioreactor having a highvolume, for example, a volume greater than 50 Liters. As the volume ofthe bioreactor increases, the total gas flow rate increases and a largeamount of moisture-containing gas stream is generated. Therefore, asystem and method for high efficiency moisture condensation isdesirable. Another scenario when the advantages are significant isrelated to the flow rate of the gas required per bioreactor volume. Forexample, a mammalian culture generally has a lower flow rate requirementper bioreactor volume regardless of the absolute size of the bioreactorthan a low rate requirement for microbial cultures. A typical mammaliancell culture bioreactor run may require 0.1 Liters of gas flow rate perLiter of bioreactor volume. For typical microbial cultures this ratio ismuch higher. For example, a microbial culture may require 1.5 Liters ofgas flow per Liter of bioreactor volume. Thus for reactions involvingmammalian cell cultures, the condensate recycling would be useful inmany cases especially as the bioreactor volume gets larger, while forreactions involving microbial cultures the condensate recycling would beuseful in almost all cases regardless of the bioreactor size.

In FIG. 1, a contact condenser container 13 is fluidically coupled to abioreactor 10 through an exhaust line 21. A condensate accumulator 16 isfluidically coupled to the contact condenser container 13 through atleast a first condensate line 23 and a second condensate line 25; thecondensate accumulator 16 is further fluidically coupled to thebioreactor 10 through at least a condensate overflow line 26. Acondensate flow control device is used to direct and/or control the flowof the condensate. The condensate flow control device may comprise apump, a check valve, a nozzle, or a pressurized air source, or acombination thereof. The exhaust line 21, the condensate lines (23 and25), and the condensate overflow line 26 described herein may also bereferred to as conduits, tubings, or flexible tubings.

A relatively hot moisture-containing gas steam leaving the bioreactor 10exits from a headspace 11 of the bioreactor and enters the contactcondenser container 13 via the exhaust line 21 in a flow direction of110. The moisture in the gas stream is condensed inside the contactcondenser container 13 to form a relatively cool condensate. A dry gasstream flows out of the contact condenser container 13 and enters afilter 18 via a fluid line 22.

In one embodiment, in the initial stage of the condensate recycling,after the relatively cool condensate is generated in the contactcondenser container 13, it is released or drained into the firstcondensate line 23 and flows to a first pump 14 disposed on the firstcondensate line 23. The first pump 14 pumps the relatively coolcondensate into the condensate accumulator 16. All or a portion of therelatively cool condensate may then be transferred back into and mixedwith the relatively hot moisture-containing gas stream via the secondcondensate line 25. The release and flow of the cool condensate leavingthe condensate accumulator 16 to be mixed with the gas stream may bedirected and/or controlled by a second pump 15 disposed on the secondcondensate line 25. Pumps 14 and 15 may be the same or different. Theflow rate of each pump can be set at a fixed speed, or a variable speedin which the speeds could be varied during the course of a bioreactorrun either manually or under the control of a bioreactor control system.

The mixing of the cool condensate with the moisture-containing gasstream may occur in the exhaust line 21 by using a spray nozzle 12. Thespray nozzle 12 is configured to produce and deliver a spray of coolcondensate droplets into the gas stream. One or more spray nozzles maybe used to spray the cool condensate back into the moisture-containinggas stream in the exhaust line 21. The nozzle spray pattern used forspraying the condensate could be one of those commonly used in otherspray applications. Nozzle spray patterns that could be used with thecontact condenser container may include, for example, Full Cone, FlatFan or Mist/Fog. The nozzle(s) could have either a single orifice orcould have multiple spray orifices built into the nozzle as is common inother spray applications.

Further in FIG. 1, the condensate accumulator 16 is fluidically coupledto the bioreactor 10 through at least the condensate overflow line 26. Acondensate overflow control device, for example, a check valve 17, isdisposed on the condensate overflow line 26; the check valve 17 isconfigured to direct the overflow of the cool condensate from thecondensate accumulator 16 to the bioreactor 10.

The first pump 14 and the second pump 15 may operate at a fixed ratedifferent from each other. The first pump may operate at a higherflowrate than the second pump. This difference in flowrates would causea slow build-up of condensate and pressure in the condensate accumulator16. At first when the condensate level in the condensate accumulator 16is still below that of an overflow exit port (not shown), pressure willcontinue to increase until it reaches the cracking pressure of the checkvalve 17 and the check valve 17 will open. Air will now flow into thebioreactor through the condensate overflow line 26 until it has reducedthe pressure in the condensate accumulator 16 to a point where the checkvalve 17 closes and the condensate leaving the contact condensercontainer 13 continues to flow into the condensate accumulator 16. At alater point the condensate collected will fill the condensateaccumulator 16 to a level where the overflow exit port (not shown) islocated. In this case when the pressure of the condensate accumulator 16reaches the cracking pressure of the check valve 17, the check valve 17opens, and some of the condensate in addition to the air will be forcedto flow through the condensate overflow line 26 and into the bioreactor10. From this point on the level of the cool condensate in thecondensate accumulator 16 will not increase above an overflow mark (notshown) since some of the condensate will also flow into the bioreactor10 whenever the check valve 17 opens but the flow rate of the overflowcondensate from the condensate accumulator 16 to the bioreactor 10 canincrease.

The check valves 17 disposed in the condensate overflow line 26 may bethose commonly used in applications where a flow in one direction onlyis desired. Non-limiting examples of check valves include ball checkvalves (spring loaded or non-spring loaded) and diaphragm check valves.The check valves may be sterilized using sterilization methods that arecommonly used to sterilize disposable, single use products. Examples ofsterilization methods include, but are not limited to,gamma-irradiation, autoclaving (moist heat), ethylene oxide gas,chlorine dioxide gas, ozone gas, and vaporized hydrogen peroxide.

The check valve 17 would require a cracking pressure lower than themaximum operating pressure of the condensate accumulator 16 andassociated tubings, but one that is higher than the maximum internaloperating pressure inside the bioreactor 10.

A non-limiting example of maximum internal operating pressure of adisposable or single use bioreactor and a disposable or single usecontact condenser container may be about 1.0 psi or less. The maximumoperating pressure of a flexible silicone tubing such as one used in asingle use system may be in the range of about 20 to 30 psi. A rigidcondenser accumulator may have a maximum pressure of about 10 to 15 psi.A flexible condenser accumulator container such as a small bag may havea maximum pressure of about 5 psi.

In FIG. 2, the recycled condensate is shown to be introduced back intoand/or mixed with the moisture-containing gas stream inside the contactcondenser container 13 rather than in the exhaust line 21.

The spray nozzle 12 may be positioned and configured such that therecycled condensate may be sprayed across the flow of the gas stream,with the flow of the gas stream or against the flow of the gas stream asthe gas stream passes through the exhaust line 21 and into the contactcondenser container 13.

FIG. 3 is a partial cross sectional view of an example of a systemaccording to an embodiment. Similar to the embodiment disclosed in FIG.2, the spray nozzle 12 is attached directly to the contact condensercontainer 13 in FIG. 3. The recycled condensate is sprayed into thecontact condenser container 13 with the spray nozzle 12, and is mixedwith the moisture-containing gas stream as the gas stream passes throughthe contact condenser container 13.

An optional screen 48 may be disposed inside the contact condensercontainer 13 to provide additional turbulence to the gas stream and toprovide a rough surface onto which droplets of the sprayed condensatecan cling to. This increases the residence time of the recycledcondensate in the gas stream to further increase cooling and mixingefficiency.

In FIG. 4, a cooler 30 is shown to provide cooling to the condensateaccumulator 16 and to further cool the condensate inside the condensateaccumulator 16 before the condensate is introduced back into and/ormixed with the moisture-containing gas stream. Further cooling thecondensate increases the efficiency of the moisture condensation whenthe cooled condensate comes into contact with the containing gas stream.The cooler 30 shown in FIG. 4 may be applied to other embodiments.

The cooler 30 may be disposed externally to the condensate accumulator16 and in direct contact with at least one outer surface of thecondensate accumulator 16. For example, the cooler 30 may comprise asupport structure (such as one or more plates or a container with anopen top, not shown) with which the condensate accumulator 16 is placedin contact with. A cooling device such as a thermoelectric Peltiermodule may be attached to the walls of the support structure to providethe cooling.

In FIG. 5, a pressurized air source 31 supplying pressurized air isfluidically coupled to the condensate accumulator 16. The additionalpressure created by a flow of the pressurized air applied to thecondensate accumulator 16 ensures that the pressure in the condensateaccumulator 16 is sufficiently high to crack open the check valve 17 andforce the condensate overflow to enter the bioreactor 10 against thepressure within the bioreactor 10. In some embodiments the pressurizedair may be sterile.

A pressure sensor 32 may be coupled to the condensate accumulator 16 andused to monitor or provide a feedback for controlling the flow of thepressurized air to the condensate accumulator 16. The pressure sensor 32may be further coupled to bioreactor system controller(s) (not shown) toallow the bioreactor system controller(s) to control the flow of thepressurized air to the condensate accumulator 16. Alternative pressurecontrol mechanisms such as a low pressure gas regulator (not shown) mayalso be used with the pressure sensor 32 to control the flow of thepressurized air into the condensate accumulator 16.

In addition, the pressure sensor 32 may be used as a safety feature toensure that the pressure inside the condensate accumulator 16 does notexceed the maximum operating pressure of the condensate accumulator 16.If the pressure inside the condensate accumulator reaches its maximumoperating pressure as detected by the pressure sensor 32 then the flowof the pressurized air into the condensate accumulator 16 is stopped.The pressure sensor 32 shown in FIG. 5 may be applied to otherembodiments.

In FIG. 6, the condensate overflow line 26 comprises a length of tubingconfigured with a U-shaped bend and held in place through external clips(not shown) to form a trap 34. The trap 34 is configured to preventbackflow from the bioreactor 10 into the condensate accumulator 16 viathe condensate overflow line 26. For example, the height (H) of the trap34 may be configured to sufficiently overcome the maximum headspacepressure (P) of the bioreactor 10, where H (ft)/2.31>P (psig) with ftand psig denotes the unit for H and P, respectively. The pressure in theheadspace 11 of the bioreactor 10 may be monitored by a bioreactorsystem controller (not shown). A non-limiting example of the maximumheadspace pressure in a single use or disposable bioreactor may be about1.0 psi or less, and a non-limiting example of the height of the trap 34may be about 1.6 feet. When the condensate level in the condensateaccumulator 16 reaches the overflow exit port (not shown), thecondensate will fill the condensate overflow line 26 and gravity feeddown to the trap 34 and into the bioreactor 10. Although a U-shaped bendis shown here as an example, one skilled in the art would appreciatethat other forms and shapes could achieve the same purpose of preventingthe backflow from the bioreactor 10 to the condensate accumulator 16.Traps with such other forms and shapes are intended to be includedwithin the scope of the present invention.

In FIG. 7, the pressurized air source 31 is coupled to a spray nozzle 40to create a nozzle system such as a siphon fed nozzle system. A siphonfed nozzle system may use a flow of the pressurized air introduced intoa stream of condensate in the nozzle 40 to create a pressure drop whichwould pull or draw the condensate from the condensate accumulator 16.The check valve 17 is shown coupling the spray nozzle 40 to thecondensate accumulator 16. When the pressurized air source 31 is appliedto the spray nozzle 40, the expansion of the pressurized air in thespray nozzle 40 creates a pressure drop which draws the recycledcondensate through the check valve 17 from the condensate accumulator 16to provide a fluid spray of the recycled condensate flowing fromcondensate accumulator 16.

In addition, the air pressure drop created as the stream of air exitsfrom the nozzle provides additional cooling capacity to the recycledcondensate as the pressurized air expands at the nozzle orifice and issprayed into the moisture-containing gas stream.

In this embodiment, the condensate accumulator 16 is shown to be locatedabove or at a level close to the level of the spray nozzle 12 so thatthe condensate is drawn into the spray nozzle 12 without the need towork against gravity. However, one of ordinary skill in the art wouldappreciate that the check valve 17 in this embodiment could be replacedwith a pump to draw the condensate into the spray nozzle 12 against thegravity.

FIG. 8 and FIG. 9 show the partial cross-sectional view and the partialexploded view, respectively, of the example in FIG. 7. In FIG. 8, theflow direction of the recycled condensate entering the condensate line25 is shown to be parallel to the flow direction of themoisture-containing gas stream entering the exhaust line 21 as anexample, but other configurations of the flow directions are possibleand are intended to be included within the scope of the presentinvention. For example, the flow direction of the recycled condensatemay be across (perpendicular to) or parallel to but in opposition to theflow direction of the gas stream.

In FIG. 8 and FIG. 9, an embodiment of a siphon fed nozzle systemassembled with commercially available parts is shown. The nozzle systemcomprises, for example, a siphon fed nozzle 40, an air feed sealing cap41, a reduced barbed Tee Tube Fitting 42, and a barbed Tee Tube Fitting43 (Nordson Medical, Loveland, Colo.). However, parts comprising one ormore custom designed injection molded plastic parts may also be used.

In FIG. 10, a recycled condensate from the condensate accumulator 16 isintroduced back into the moisture-containing gas stream by using thesecond pump 15. However, instead of being sprayed into the gas stream,the recycled condensate is allowed to drip, or run down the interiorsides of the exhaust line 21 by gravity.

FIG. 11 and FIG. 12 show the partial cross-sectional view and thepartial exploded view, respectively, of the example in FIG. 10. In FIG.11, the flow direction of the recycled condensate entering thecondensate line 25 is shown to be in a direction across (perpendicularto) the flow direction of the gas stream entering the exhaust line 21 asan example, but other configurations of the flow directions are possibleand are intended to be included within the scope of the presentinvention. For example, the flow direction of the recycled condensatemay be along (parallel to) the flow direction of the gas stream.

Optionally, at least one screen 50 may be disposed inside the interiorof the exhaust line 21, with the screen 50 positioned to allow the flowof the recycled condensate leaving the condensate accumulator to passover and collect on the screen(s). The condensate may also be allowed tosimply run along the inside wall of the exhaust line 21. The optionalscreen 50 and a barbed Tee Tube Fitting 51 in FIG. 12 are shown here forillustration purpose only. Many other alternative configurations may beused in the present invention, including, for example, a screen woundinto a tubular spiral, a screen folded into a lobed tubular shape, ascreen folded into a pleated shape, a screen assembly as a series ofstacked, circular discs, or a spiral, spring shaped coil.

In FIG. 13, a pump fed nozzle system is shown. The pump 15, when usedwith or without the assistance of the pressurized air source 31, pushesor drives the recycled condensate through a spray nozzle 60 and producesa spray of the condensate in the moisture-containing gas stream. Thisconfiguration is different from the siphon fed nozzle system shown inFIG. 7, where the flow of pressurized air through the spray nozzle 40draws the condensate into the spray nozzle 40.

During the early stages of a bioreactor run when not much condensate hasbeen generated the expansion of the pressurized air in the spray nozzlewill have some cooling effect on the flow of the air and will by itselfassist to some extent in condensing the moisture from the gas stream.

FIG. 14 and FIG. 15 show the partial cross-sectional view and thepartial exploded view, respectively, of the example in FIG. 13. In FIG.14, the flow direction of the recycled condensate entering thecondensate line 25 is shown to be in a direction across (perpendicularto) the flow direction of the gas stream entering the exhaust line 21 asan example, but other configurations of the flow directions arepossible. For example, the flow direction of the recycled condensate maybe along (parallel to) the flow direction of the gas stream or parallelto but in opposition to the flow direction of the gas stream.

In FIG. 14 and FIG. 15, an embodiment of the pump fed nozzle systemassembled with commercially available parts is shown. The nozzle systemcomprises, for example, a barbed Tee Tube Fitting 63 (Nordson Medical,Loveland, Colo.). However, parts comprising one or more custom designedinjection molded plastic parts may also be used.

In FIG. 16, the condensate accumulator is replaced with a tubing “Y”fitting or “T” fitting 35. In this embodiment, the first pump 14operates at a higher speed than the second pump 15. The first pump 14directs the condensate from the contact condenser container 13 to thefitting 35 in such a manner that the ratio of the flowrate of the secondpump 15 to the first pump 14 correlates with the amount of condensaterecycled back into the gas stream. The remaining condensate that is notrecycled back into the gas stream is returned to the bioreactor 10through the condensate overflow line 26. The condensate that is beingpumped back into the gas stream may be pumped directly into the exhaustline 21 or through the spray nozzle 12 to form a spray of condensatedroplets. The spray nozzle 12 may also be configured to be used with thepressurized air source 31 to assist disperse a small volume of therecycled condensate to form a spray of condensate droplets that may notbe achieved by using the pumps alone.

FIG. 17 is a perspective view of a disposable contact condensercontainer 13. The contact condenser container 13 is shown to comprise aninlet port 70 and an outlet port 72 located on the outer wall of thecontact condenser container 13 and allows a moisture-containing gasstream to enter and exit the contact condenser container 13, and a port71 for the cool condensate to exit the contact condenser container 13.The contact condenser container 13 further comprises an internal coolingdevice 75 (an example of 75 is shown in FIG. 18) with two ending ports73, 74 which may act as an inlet port or an outlet port to allow acoolant to flow through the internal cooling device 75 to provideadditional cooling and promote the condensation of moisture in the gasstream passing through the contact condenser container 13.

FIG. 18 is an exploded view of a contact condenser container accordingto one embodiment. The internal cooling device 75 is disposed within thecontact condenser container 13 to promote the condensation of moisturein the gas stream passing through the contact condenser container 13,and also serves to increase the turbulence within the gas stream as itpasses through the contact condenser container 13.

In FIG. 18, the internal cooling device 75 is shown in a form of alength of a tubing and configured to have a serpentine shape such thatit substantially completely fills the gap between the two inner layersof the contact condenser container 13. The contact condenser containerassembly may further includes at least one screen 48 disposed inside thecontact condenser container 13, the screen 48 is configured to allow thecondensate generated from the moisture-containing gas stream to becollected on the screen 48 before the condensate exits the contactcondenser container 13. Allowing the condensate to be collected on andcling to the screen 48 increases the residence time of the condensate inthe gas stream which increases the cooling and mixing efficiency of thecontact condenser container 13.

Other internal cooling device structure may be arranged to allowcondensation to form thereon, and/or to increase turbulence.Non-limiting examples include a series of fins attached to a support,and a spiral coil. The internal cooling device 75 may be flexible,rigid, or semi-rigid. Any structure within the contact condensercontainer 13 that can promote turbulence and/or promote moisturecondensation is within the scope of the invention.

In addition, the contact condenser container 13 may be used inconjunction with an external cooling source to lower the temperature ofa moisture-containing gas stream entering or leaving a bioreactor,further increasing the efficiency of the moisture condensation withinthe contact condenser container 13. In one embodiment, at least onesurface of the contact condenser container 13 is in contact with anexternal cooling source, for example, at least one cold plate (notshown), which by conduction cools at least one surface, for example topsurface of the contact condenser container 13, which in turn cools theinside surface of the contact condenser container 13 and cools themoisture-containing gas stream to or below its dew point temperature asthe moisture-containing gas stream flows over the cooled surface.

In one embodiment, the at least one cold plate is appropriately sized toapproximately match the surface area of one side of the contactcondenser container 13 to maximize its contact area with the contactcondenser container 13. The at least one cold plate may be attached tothe cold side of a thermoelectric Peltier module.

In another embodiment, provision is made on the cold plate to provide ameans of securing the contact condenser container 13 in position on thecold plate in order to ensure that at least one surface of the contactcondenser container 13 is in contact with the cold plate surface.

In yet another embodiment, the least one cooling plate has a baffledpattern configured to direct a flow path within an interior chamber ofthe contact condenser container 13. The contact condenser container 13may be sandwiched between two cooling plates.

FIG. 19 is a perspective view of an example of a condenser accumulatoraccording to one embodiment. In FIG. 19, a rigid condensate accumulator27 has a first condensate port 76 through which a cool condensateleaving the contact condenser container 13 is added to the condensateaccumulator 27. The condensate accumulator 27 also has an optionalpressurized air flow port 77 through which a flow of sterile pressurizedair may be applied to pressurize the condensate accumulator 27 ifneeded. Near the bottom of the condensate accumulator 27 is a secondcondensate port 78 that allows the condensate to flow out of thecondensate accumulator 27 to the contact condenser container 13. Acondensate overflow port 79 is located near the top of the condensateaccumulator 27 and the location of the condensate overflow port 79 onthe condensate accumulator 27 is higher than that of the secondcondensate port 78. The condensate overflow port 79 ensures that thelevel of condensate in the condensate accumulator 27 does not fill abovea condensate overflow line (not shown) in the condensate accumulator 27.

FIG. 20 shows one representative embodiment of a flexible condensateaccumulator 28, with similar structural components as described for therigid condensate accumulator 27. Also similar to the rigid condensateaccumulator 27, the flexible condensate accumulator 28 may also comprisean optional pressurized air flow port (not shown) through which thesterile pressurized air may be applied to pressurize the condensateaccumulator 28 if needed.

FIG. 21 is a perspective view of an example of a condensate primingsystem according to an embodiment. The condensate priming system 100 maybe part of a gas condensation system such as the one shown in FIG. 1.For example, the condensate primer 100 may be disposed anywhere in thecondensate lines, for example, in the first condensate line 23 as shownin FIG. 1, between the contact condenser container 13 and the condensateaccumulator 16, or in the second condensate line 25 between thecondensate accumulator 16 and the contact condenser container 13. Otherlocations in the condensate flow path may also be used for disposing thecondensate priming system 100.

The condensate priming system 100 comprises a priming fitting 82, alength of tubing 83, a sterile filter 84, a sterile connector 85, and aconnector end cap 86. The sterile filter 84 keeps the condensate lines(for example, 80) sterile when priming with water and/or the coolcondensate. The sterile connector 85 may be a Luer connector. However,other sterile connectors, for example, Pall Kleenpak connectors orColder AseptiQuik sterile connectors, may also be used.

FIG. 22 is a schematic drawing of an example of a method of condensingmoisture in a gas stream entering or leaving a bioreactor, according toan embodiment. The method includes the steps of: directing the gasstream leaving the bioreactor and entering the contact condensercontainer; producing a condensate inside the contact condensercontainer; directing and controlling a flow of the condensate leavingthe contact condenser container and entering the condensate accumulator;and directing and controlling a flow of at least a portion of thecondensate leaving the condensate accumulator to be mixed with the gasstream.

The specific embodiments described above have been shown by way ofexample, and it should be understood that these embodiments may besusceptible to various modifications and alternative forms. It should befurther understood that the claims are not intended to be limited to theparticular forms disclosed, but rather to cover all modifications,equivalents, and alternatives falling within the spirit and scope ofthis disclosure.

What is claimed is:
 1. A system for condensing moisture in a gas streamentering or leaving a bioreactor, the system comprising: a contactcondenser container fluidically coupled to the bioreactor through anexhaust line; a condensate accumulator fluidically coupled to thecontact condenser container through at least a first condensate line anda second condensate line; the condensate accumulator further fluidicallycoupled to the bioreactor through a condensate overflow line; a firstcondensate control device disposed on the first condensate line andconfigured to control a flow of condensate leaving the contact condensercontainer and entering the condensate accumulator; and a secondcondensate control device disposed on the second condensate line andconfigured to control a flow of condensate leaving the condensateaccumulator to be mixed with the gas stream.
 2. The system of claim 1,wherein the bioreactor, the condenser accumulator, or the contactcondenser container, or a combination thereof is disposable.
 3. Thesystem of claim 1, wherein the first condensate control device and/orthe second condensate control device comprises a pump, a check valve, anozzle, or a pressurized air source, or a combination thereof.
 4. Thesystem of claim 1, further comprising a condensate overflow controldevice disposed on the condensate overflow line and configured tocontrol a flow of condensate leaving the condensate accumulator andentering the bioreactor.
 5. The system of claim 4, wherein thecondensate overflow control device comprises a pump, a check valve, anozzle, or a pressurized air source, or a combination thereof.
 6. Thesystem of claim 1, further comprising a cooler configured to providecooling to the condensate accumulator.
 7. The system of claim 1, furthercomprising a pressurized air source configured to provide a flow ofpressurized air.
 8. The system of claim 7, further comprising a pressuresensor coupled to the condensate accumulator and configured to provide afeedback for controlling the flow of pressurized air.
 9. The system ofclaim 1, wherein the condensate overflow line comprises a length oftubing forming a trap.
 10. The system of claim 1, further comprising: anozzle configured to produce the flow of condensate leaving thecondensate accumulator in a form of a spray of condensate droplets. 11.The system of claim 10, wherein the nozzle is a siphon fed nozzle. 12.The system of claim 10, wherein the nozzle is a pump fed nozzle.
 13. Thesystem of claim 10, wherein the flow of condensate leaving thecondensate accumulator to be mixed with the gas stream is directed intoa location in the exhaust line.
 14. The system of claim 10, wherein theflow of condensate leaving the condensate accumulator to be mixed withthe gas stream is directed into the contact condenser container.
 15. Thesystem of claim 1, wherein the flow of condensate leaving the condensateaccumulator to be mixed with the gas stream is in a form of a gravityflow down the interior sides of the exhaust line.
 16. The system ofclaim 15, wherein at least one screen is disposed adjacent to theinterior sides of the exhaust line.
 17. The system of claim 1, furthercomprising an internal cooling device disposed inside the contactcondenser container, wherein the internal cooling device comprises alength of tubing or a spiral coil, or a combination thereof.
 18. Thesystem of claim 1, wherein the contact condenser container is used withan external cooling device comprising at least one cooling plate,wherein the at least one cooling plate has a baffled pattern configuredto direct a flow path within an interior chamber of the contactcondenser container.
 19. The system of claim 18, wherein the externalcooling device comprises two cooling plates, and the contact condensercontainer is sandwiched between the two cooling plates.
 20. The systemof claim 1, wherein the condenser accumulator is rigid.
 21. The systemof claim 1, wherein at least one of the contact condenser container, thecondensate accumulator, the exhaust line, the first condensate line, thesecond condensate line, or the condensate overflow line, or acombination thereof is made of gamma-irradiation stable materials.
 22. Amethod of condensing moisture in a gas stream entering or leaving abioreactor, the method comprising: directing the gas stream leaving thebioreactor and entering a contact condenser container; producing acondensate inside the contact condenser container; directing andcontrolling a flow of the condensate leaving the contact condensercontainer and entering a condensate accumulator; and directing andcontrolling a flow of at least a portion of the condensate leaving thecondensate accumulator to be mixed with the gas stream.
 23. The methodof claim 22, further comprising: directing and controlling a flow ofoverflow condensate leaving the condensate accumulator and entering thebioreactor.
 24. A system for condensing moisture in a gas streamentering or leaving a bioreactor, the system comprising: a contactcondenser container fluidically coupled to the bioreactor through anexhaust line; a junction fitting fluidically coupled to the contactcondenser container through a first and a second condensate line; thejunction fitting further fluidically coupled to the bioreactor through acondensate overflow line; a first condensate control device disposed onthe first condensate line and configured to control a flow of condensateleaving the contact condenser container into the junction fitting; and asecond condensate control device disposed on a second condensate lineand configured to control a flow of condensate to be mixed with the gasstream.
 25. The system of claim 24, wherein at least one of thebioreactor, the junction fitting, or the contact condenser container, ora combination thereof is disposable.